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E39 (1997 - 2003) The BMW 5-Series (E39 chassis) was introduced in the United States as a 1997 model year car and lasted until the 2004 when the E60 chassis was released. The United States saw several variations including the 525i, 528i, 530i and 540i. -- View the E39 Wiki

I think I created a bigger problem while trying to replace the belts in the car. Was trying to replace the AC and Main serpentine belt.

Looked online and did not find clear directions on how to remove the fan shroud and fan. I found c90's Diy, but he started with after removing the fan shroud. Anyway found Besian's instructions and was following those.

However, when I came to unhooking the clip from the radiator, I managed to break something ..

Pic 1 (A) Shows the clip / part I was trying to open
Pic 1 (B) shows the area which snaped / broke

I looked at the website (autohaus) ad searching for radiator shows a part , radiator hose.. is it possible to replace this part without replacing the whole radiator ? Part number shown is 0005000894 (Radiator Hose, 90 Degree Elbow Fitting on Top of Radiator for Drain).

How would get the broken piece out?

Also, how do I disconnect the expansion tank from the fan shroud? Is it attached via a screw or something to the fan shroud? I managed teo disconnect the fan shroud, but the expansion tank is still stuck to it (opened the bleeder screw already).

There are two little tabs, one on either side of the bleeder screw, when both are pushed GENTLY toward the screw, the clip that holds the expansion tank will lift off. As far as that elbow, my 540 is different, but it does indeed look like you may be able to just replace the small part. Quite a savings of time and money if it works. For $2, I would sure give it a try. I might even go to the dealer and pay full price to get the item right away. I checked my Bentleys and its no help on replacing this item, but once you have a new one in hand you should see how it was held in, and poss how to get the broken part out. Good Luck.

And if you have never done a cooling system overhaul this maybe the car's way of giving you a hint.

I've been exhorting Cam to buy a newer E39 so that his instructions would exactly fit ours (mine is a 2002 525, yours a 2003). I think we later-model E39 owners need to gather up a fund to buy a junkyard 1999 to 2003 project car for Cam so he can write that DIY we need! The Bentleys are not enough or people like me (who don't have much experience)...

The point is, there is apparently a dearth of step-by-step DIYs for our model years (maybe it's time we write 'em!)...

PS: Next time for belt replacement, no need to play with the radiator nipple.
- Remove the Fan Clutch and set it inside the fan shroud.
- Remove bottom splash shield to make access to AC belt easier (car on wood ramps).
- Change belts.

The expansion tank fits into a slot on the fan shroud and and be removed by pulling it up towards you but ONLY after you disconnect the two hoses connected to the bottom of the tank. The hoses are held by metal clips which should be visible when you shine a light down towards them. If you are going to remove the expansion tank, have some coolant ready as you are going to loose a lot of it when removing the expansion tank.
Let me know if you need more help.

I am off hunting to see if the stealer or any of the indy's locally have the 90 degree part.. hoping someone locally has it as opposed to waiting to get it shipped..
once I get it.. Do i just shove it in ?? or is there a procedure for it ?

Already lost a lot of coolant from the broken nipple .. and I had just gotten a coolant flush done .. :-(

Put a little of grease on the nipple O-ring and slide it in.
When clamping the hose back (factory is "Oetiker" type clamp), you can use a standard clamp. Just clamp it snugly but remember to turn the screw side down, otherwise you won't be able to refit the fan shroud.

Um, this is a real bummer since I changed both belts in a matter of minutes with no more than a wrench or two to release the tensioners. I didn't take ANYTHING off and was able to do both belts just fine. Sorry to hear you caused more damage than good.

I think I created a bigger problem while trying to replace the belts in the car. Was trying to replace the AC and Main serpentine belt.

Looked online and did not find clear directions on how to remove the fan shroud and fan. I found c90's Diy, but he started with after removing the fan shroud. Anyway found Besian's instructions and was following those.

Well, the belts can be changed without removing the fan and fan shroud. You can loop the accessory belt out through the existing opening/space. I did it that way, surprising easy. I have a 2003 525i also.

Finally done.. found the replacement nipple at the dealership ($3.10) ... part # 17-11-0-419-132 .. does not show up in RealOEM or any of the pics the dealer has..

The AC belt can be easily done from the bottom .. next time around I will try the main belt without taking the fan shroud out ... This was first time replacing belts on any car.. hopefully next time things will be smoother..

Managed to break the nipple while trying to open the original Oetiker clamp .. did replace with the clamp shown in c90's pic

Well, the belts can be changed without removing the fan and fan shroud. You can loop the accessory belt out through the existing opening/space. I did it that way, surprising easy. I have a 2003 525i also.

Yes,

But if there is already anti-seize on the fan clutch, removing the fan cluth is a 30-second job.
Then the belt job is much much easier with the fan clutch off resting inside the fan shroud.

RE: Nipple PN 17-11-0-419-132. When you buy a new radiator (Behr or Nissens), the nipple is included with it.
This is why it is not found in realoem.com.

BTW, seriously check all service records and do a cooling overhaul.
Your broken nipple is basically the 1st "brush with death" experience.

Not to start a fire storm, but my 43 year old Austin Mini sat for 28 years on a shelf in a barn. I put the engine back in (from the barn basement) and drove it over 20,000 miles. Granted I replaced the water hoses and clutch plate, but why are these e39s like a Ming vase in an earthquake? Though they are far more technologically advanced, is the plastic really that delicate? Is the metal less quality?

HA!
I did that!
Broke that little L piece!
I was installing the replacement vanos seals at the time, and was removing the fan and shroud.
I had to flush the expansion tank to get all the plastic bits out!
Good times!

trying to replace the belts in the [2003 525i] ...
Looked online and did not find clear directions on how to remove the fan shroud and fan. I found c90's Diy, but he started with after removing the fan shroud. Anyway found Besian's instructions and was following those.

Just for the record, for my 2002 525i, today, with a LOT of ad-hoc help, I removed both belts and alternator without touching the fan shroud so it certainly can be done leaving the radiator components in place (despite what it says in the Bentleys).

I only removed the viscous fan clutch using the special 32mm thin long wrench and held the fan bolts with another special tool; but otherwise it didn't require anything special.

The belts, pulleys, and tensioners can be replaced with only the removal of the fan/clutch

BTW, how DO you replace the tensioner itself with the fan shroud in place?

I removed the fan (and placed it inside the radiator well); but I tried to remove the pulley on the lower mechanical tensioner but with the T50 Torx in place, the fan shroud lip was 1/8" away from the end of the socket, making it impossible to get a wrench on the T50 Torx.

With the fan shroud in place, how does one remove the mechanical tensioner pulley then?